The document discusses conveyor technologies for pretreatment (PT) and electrocoating (ED) systems. It outlines the advantages of variable dipping systems like the E|Shuttle over continuous and discontinuous fixed conveyor systems. The E|Shuttle uses electric monorail technology to allow three degrees of freedom for dipping parts, improving process quality. It has been sold to multiple automakers worldwide for its flexibility, quality, and efficiency. Requirements for conveyor flexibility are increasing due to new body materials and designs, making the E|Shuttle well-suited to meet rising industry demands.

1. The E|Shuttle conveyor technology
for PT and ED
Miguel Gil
g
Barcelona, 17.11.2011

2. Agenda
Overview of different conveyor technologies for PT and ED systems
Continous conveying systems
Discontinous conveying systems
Di ti i t
Decisive advantages of variable dipping systems
The E|SHUTTLE system
References
Summary

3. Overview of different conveyor technologies
Continous Discontinous
conveying systems
i t conveying systems
i t Running Lifting Rotating
Variable Dipping Systems
VarioShuttle
E|Shuttle
Rotation Systems
Competition´s system Competition´s system
Horizontal
Hori ontal Dipping S stems
Systems
Monorail / Power&Free Programmable Hoists
Pendulum EMS

4. Variable Dipping Systems · Decisive Advantages
Conventional dipping curve with Optimized curve with variable
horizontal conveying system dipping system
Air bubble No air bubble
Improved process quality thanks variable dipping systems
p p q y pp g y

5. Variable Dipping Systems · Decisive Advantages
Horizontal conveyors and
rotating systems
g y Variable dipping systems
Roof Roof Roof Roof
up down up down
PT X PT X X
ED X ED X X
limited orientation of body caused by Each combination and body orientation is
predefined dipping curve possible

6. Variable Dipping Systems · Decisive Advantages
OEMs value the advantages of a variable dipping system:
1. Customer A 2. Customer B
Roof Roof Roof Roof
up down up down
PT X PT X
ED X ED X
Change of the body orientation is for „Roof up“-orientation is for
this customer essentail to fullfill this customer necessary to minimize
the quality requirements the dynamic forces on the body

7. E|SHUTTLE
The concept
Conveyor system based on
the electric monorail system
(EMS) with 3 degrees of
freedom
Vertical dipping movement
with lifting gear
Advanced control system
Space-saving,
Space-saving compact design
Tunnel mounted on the tank
construction
With lamellar seal separating
the trolley

8. E|SHUTTLE
Individual dipping curves
Roof up
Roof down
Any tilted position
Technical Benefits
Optimal corrosion protection Skidless passage possible
Optimal ED spread Optimal layout possibilities
No ED sanding TCO reduction

9. E|SHUTTLE
Technical data
EMS
Payload: 1,000 kg (body with skid) Traverse
Capacity: No restrictions (only those
dictated by the process) Lifting carriage
Speeds
Travel: variable up to 60 m/min (max.)
Lifting/lowering: variable up to 15 m/min Lamellar seal
Lifting post
Turning: 20°/sec (max.) Lifting arm
Net weight: approx. 3.5 t
Rotating arm
Support frame

10. E|SHUTTLE
System width with return line
(for bodies with a width of 2,100 mm):
System height depends on
Position of body for draining
Skid and body length
Required space
A = 10,000 – 12,000 mm
B = 9,800 mm
C = 2,150 mm A
C
B

11. E|SHUTTLE
Cross-section and layout from references 1
1 Cross section with body in draining position
Cross-section
2 Layout for dip-coating
3 L tf t t t
Layout for pretreatment
33.500
2
72.000
3

12. E-Shuttles already sold
Volkswagen Group of America, Chattanooga, TN, USA
Pretreatment 16 Shuttles
EC 12 Shuttles
Porsche, Zuffenhausen, Germany
Pretreatment 8 Shuttles
EC 6 Shuttles
Volkswagen Slovakia, Bratislava, Slovakia
g , ,
Pretreatment 21 Shuttles
EC 13 Shuttles
Daimler, Kecskemet, Hungary
Pretreatment 19 Shuttles
EC 11 Shuttles
Volkswagen do Brasil, Taubaté, Brasil
Pretreatment 34 Shuttles
EC 24 Shuttles
MB do Brasil, Juiz de Fora, Brasil
Pretreatment 7 Shuttles
EC 3 Shuttles
FAW-VW, Foshan
FAW VW Foshan, China
Pretreatment 34 Shuttles
EC 24 Shuttles
Total 232 Shuttles

13. E|SHUTTLE
The system at a glance
System with hi h fl ibilit and product quality
S t ith high flexibility d d t lit
Capacity is defined by the process:
no limits on capacity due to the transport system
Return line at the side ensures little space required
Low overall weight (steel construction EMS
construction, EMS,
lifting gear with lifting arm)
System components are known and have proved
their l
th i value
Easy programming of the dipping curves

14. Summary
Requirements for flexibility increase continously due to higher variety of models and sub-models of
carbodies.
carbodies
Reduced lifecycles of model generations leads to an increased amount of start-ups within exisiting
systems.
Current development body-in-white introduces
C rrent de elopment of bod in hite introd ces high material mi for PT/ED
mix
(Aluminium, steel, tempered steel, plastic,…).
Current development of body-in-white leads to the utilisation of materials union techniques, which
p y q
reach their final stiffness only after PT/ED (inside ED-oven).
Crash tests have lead to an increased number of smaller submodules for the body-in-white which are
difficult to be reached during ED coating.
Highest corrosion protection remains the most important requirement for the PT/ED process.
that´s why EISENMANN developed the E|Shuttle

15. Kontakt
EISENMANN Ingeniería S.A.
Miguel Gil
C/ e guedà
C/Berguedà 1. Parc de Negocis Mas Blau
ac egoc s as au
08820 El Prat de Llobregat (Barcelona)
E-Mail: miguel.gil@eisenmann.com
Internet: www.eisenmann.com
◙
15